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The decoupling characteristics of multi-electrode arc heat and mass provide a reliable approach for achieving efficient and high-quality welding and additive manufacturing. However, the presence of polar effect reduces the stability of the main arc, limiting its application. To address this issue, this paper proposes the skew-coupling arc (SCA) and conducts in-depth research on the mass transfer (MT) mechanism. The paper conducts comparative experiments to evaluate the MT capacity (MTC) of the inter-wire arc (IWA) and analyzes how characteristic parameters of the SCA influence the MT performance of the IWA. The results indicate that the MTC primarily depends on the heat generated by the IWA itself. Compared to situation without the IWA, the deposition speed can reach 15.9 m/min with a growth rate of 356 % at an input voltage of 30 V. The IWA current is linearly related to the input voltage, with a growth rate of 13.3 A/V. At the same current, the MTC of the IWA is three times greater than that of the direct current gas metal arc, and can reach 21 m/min at a current of 280 A. Notably, a segment of molten liquid is suspended at the end of the cathode wire, with its behavior intimately linked to the transition dynamics of cathode droplets. The input voltage varies from 21 V to 27 V, and the temperature of the suspension liquid increases, resulting in a decrease in surface tension and a significant reduction in size from 4.6 mm to 1.9 mm. Raising the input voltage can significantly enhance the MTC of the IWA and promote anode droplet transfer, but the spot force at the base of the cathode droplet leads to an excessive increase in droplet size, hindering effective transfer. The cathode droplet size reaches 3.9 mm at an input voltage of 30 V. By adjusting the plasma arc current and plasma gas flow rate to regulate the plasma fluid force acting on the cathode droplets, the adverse effects of the spot force can be mitigated, thereby facilitating the droplet transfer process and simultaneously improving weld formation quality. These findings are expected to establish a theoretical basis for the MT and provide methodological guidance for the practical application of SCA heat sources. © 2025 The Society of Manufacturing Engineers
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Journal of Manufacturing Processes
ISSN: 1526-6125
Year: 2025
Volume: 135
Page: 100-111
6 . 2 0 0
JCR@2022
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ESI Highly Cited Papers on the List: 0 Unfold All
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30 Days PV: 8
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